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Alright, so where I left off was getting the engine running and then got busy. One of the problems I had was figuring out where to put the clutch master cylinder and how to get everything routed, which I think I may have that covered... And then I looked in the engine bay... Spiderwebs: wire...

First off, I definitely need to apologize for dropping the ball completely with this thread, a LOT has been going on in the last year and a half. Will be posting some updates soon on the build (gotta fix an issue with my elite explorer status), finally have the time and garage set up to where it...

I DID IT, I DID IT, I FRIGGIN' DID IT!!! :D I know I'm not one who would normally be counted on to deliver, but here it is: https://www.youtube.com/watch?v=G9EbyBKsLQU On to the boring details: First things first: TIMING When I say this thing was off, I mean by a country mile. I must've...

[In best Hubert Farnsworth voice] "Good news, everyone!" (Well, aiming for it, anyways) Tomorrow may very well mark the fire-up day! I would do it tonight, but it's late and the exhaust is just a straight dump off the headers. Dropped the tank, removed the old gas (which, wow... so bad), put...

Did some more work on it today. The old battery was completely shot, wouldn't crank the engine, even when jumped. Pulled the fuel tank, found that it has an internal regulator between the pump and the outlet. Also, man did that gas do a number to some of that stuff. The fuel sock had 1/2...

Well, got going on getting it started, buuut... Problem. Took the old battery, hooked a charger up to it and poured a bunch of Epsom salt in it, maybe I can get use out of it for a short time. Mostly just testing purposes. Ran all the wires (temporarily) for the relays (PCM, FP Relay), put the...

I was thinking it might have been integrated with the in-tank pump, due to the 1 fuel feed line and no obvious return line, but the Haynes manual stated there was a FPR on the fuel rail of the 4.0 sohc. They must have changed that at some point. I may not have to run a return line at all...

Been awhile, been busy. Bought a new house, traded in my Bowtie garbage Blazer for a Super Duty, and have done a few things to the X. Not going to post pictures quite yet, but I have a few. Got the rear driveshaft cut down, but with all the projects around the new house running to the truck...

Wouldn't say "can't," but will say "shouldn't." Your main enemies are the 4wd system (can almost guarantee the front diff will be leaving), the steering system, and the electrical system... That's not including possible frame modification. Easiest way is the 5.0 swap or selling and buying an Ex...

Update: Going through the wiring right now. Not super difficult once you realize what you can cut off... which is a lot. Cut the forward section off with the fuel injector wiring "spider" and most related stuff, chased the wires I need back to the main harness. The F150 harness on the other hand...

Another update for y'all. REAR DRIVESHAFT: Thought I was going to have to use a BFH to wail on the gas tank to get clearance for the driveshaft, wrong. Just had to remove the plastic cover over the front of the tank. Thought I was going to be able to use the front driveshaft from the F150...

More pics: Top view of modded crossmember And front. Went from about 1 1/2" to 2 1/4" offset passenger to driver sides. Didn't quite take into account the drop. So much for not getting deep into modding the crossmember. Probably do that when I do the SAS though. It'll work just fine...

Tranny and t-case are in!!! (-ish...) Trans needs 2 more bolts (for the top, couldn't be 3/8", couldn't be 1/2", noooo, they had to be 7/16" :splat:), and the t-case needs 2 more bolts put in it as well. The new bolt holes I drilled... How I needed to grind the flange down so that they'd fit...

Quick update for you guys, it's been a while. Got the transmission (mostly) bolted up, had to cut even further up from the manual trans hole in the X body, figured that'd be a problem early on though. Gonna have to make a "Z" link for the shifter, unless I only want N, 2, 4, and R... Kinda...

Got all pissed off today after stopping into the insurance office and having my day ruined, so I needed a little "zen" time. Separated the t-case/tranny, drilled the hole and did a mock-up. It's basically perfect, only downside is that t-case is huge. From the bottom of the trans crossmember to...

Haven't had a lot of time recently to work on it, slammed by house work and business stuff at the moment. Decided that I'm going to clock the t-case rather than do a bunch of welding work on the trans brace. Reason being is that clocking it will reduce the front driveshaft angle when I go SAS...

Maybe try a wire wheel on a 4 1/2" grinder, followed by bead blast. The wheel will remove nearly anything not metal, the difficulty may come in finding a narrow one. Given enough force and time they can go through thin metal, but if you're careful it shouldn't... that's some honest-to-goodness...

Par for the course, still. More progress, more setbacks. Whatever. Got the trans/t-case combo out of the corner with the help of my neighbor... he was not very happy about it, even though I gave him the easy end. Probably due more to his "oh my god, what the f***!"'s. Could not help it... he'll...

As far as the "popcorn" look, I concur with either water contamination or "dry spray". Not getting a wet enough coat or depending on the heat/humidity, it can reduce your workability time with whatever you're spraying, especially if it starts to "kick" (cure) on you while it's still in the gun...

I'd be careful about heat around the driveshaft weight. Went down to the garage, wire brushed my front F150 shaft a bit to see if it was welded... Appears not. From what I've looked up, some of them are attached with adhesive. If you were to put any heat to it, you might consider having it...

Spent a little time today working on the X. Got the console removed and the blanking plate for the stick shift removed. There isn't a very long distance from the front of the trans bellhousing to the square assembly for the shift stem is (12"), but I may just barely make it. Might have to make a...

Nine hours later, I have the main meat of the mounts put in and welded. I'm going to weld some corner braces in later, but for now I can get to doing some of the other important stuff like the drivetrain components. Didn't put the engine back down because my tank is running on empty, may do that...

Been working on the main engine mounts for the last week or so. Got a rough idea of how I'm going to put them in... Definitely not going to be pretty though. Would've been a lot easier with an SAS, but I'm flying blind here, so it is what it is. The oil filter adapter worked out fairly well...

Hopefully, yeah. That's one expensive piece of aluminum...

Turns out my co-worker had exactly what I needed! Right on. Forgot to take a picture before I drilled it out, but you'll get the idea. Drilled out to 11/16" Had to file the threads on the outer portion due to the extreme force required to clamp the piece while tapping and drilling...